U.S. patent number 11,333,375 [Application Number 16/487,921] was granted by the patent office on 2022-05-17 for air conditioner.
This patent grant is currently assigned to Shinwa Controls Co., Ltd. The grantee listed for this patent is SHINWA CONTROLS CO., LTD. Invention is credited to Yasuhiro Naohara, Kenji Nishimura.
United States Patent |
11,333,375 |
Nishimura , et al. |
May 17, 2022 |
Air conditioner
Abstract
An air conditioner is provided, including an air flow path, a
cooling unit disposed in the air flow path that cools air
introduced into the air flow path to condense vapor contained in
the air, and a humidification unit that humidifies the air and
which includes a storage tank for storing water and a heater for
heating water in the storage tank. A discharged-water storage unit
is also provided, which stores water discharged from the cooling
unit and water discharged from the humidification unit, and an
exhaust pipe is connected to the storage tank and configured to
discharge water in the storage tank to the discharged-water storage
unit. An exhaust valve is disposed midway on the exhaust pipe, and
an overflow pipe connects the storage tank and a part of the
exhaust pipe on the downstream side of the exhaust valve.
Inventors: |
Nishimura; Kenji (Kawasaki,
JP), Naohara; Yasuhiro (Kawasaki, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
SHINWA CONTROLS CO., LTD |
Kawasaki |
N/A |
JP |
|
|
Assignee: |
Shinwa Controls Co., Ltd
(Kawasaki, JP)
|
Family
ID: |
1000006308673 |
Appl.
No.: |
16/487,921 |
Filed: |
December 5, 2017 |
PCT
Filed: |
December 05, 2017 |
PCT No.: |
PCT/JP2017/043714 |
371(c)(1),(2),(4) Date: |
August 22, 2019 |
PCT
Pub. No.: |
WO2018/154909 |
PCT
Pub. Date: |
August 30, 2018 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20190383502 A1 |
Dec 19, 2019 |
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Foreign Application Priority Data
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|
|
|
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Feb 23, 2017 [JP] |
|
|
JP2017-032464 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F
6/02 (20130101); F24F 13/222 (20130101); F24F
2013/225 (20130101); F24F 2013/227 (20130101); F24F
2006/008 (20130101) |
Current International
Class: |
F24F
6/02 (20060101); F24F 13/22 (20060101); F24F
6/00 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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202532640 |
|
Nov 2012 |
|
CN |
|
202532640 |
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Nov 2012 |
|
CN |
|
203478565 |
|
Mar 2014 |
|
CN |
|
203478565 |
|
Mar 2014 |
|
CN |
|
1 578 269 |
|
Nov 1980 |
|
GB |
|
S51-037764 |
|
Mar 1976 |
|
JP |
|
H06-288566 |
|
Oct 1994 |
|
JP |
|
H09-243145 |
|
Sep 1997 |
|
JP |
|
2001-141257 |
|
May 2001 |
|
JP |
|
2005-207706 |
|
Aug 2005 |
|
JP |
|
2013-053767 |
|
Mar 2013 |
|
JP |
|
5886463 |
|
Mar 2016 |
|
JP |
|
2016-114278 |
|
Jun 2016 |
|
JP |
|
Other References
Japanese Office Action (Application No. 2017-032464) dated Mar. 24,
2017. cited by applicant .
Japanese Office Action (Application No. 2017-032464) dated Jun. 9,
2017. cited by applicant .
International Search Report and Written Opinion (Application No.
PCT/JP2017/043714) dated Feb. 6, 2018. cited by applicant .
Extended European Search Report (Application No. 17897238.6) dated
Oct. 26, 2020. cited by applicant .
Chinese Office Action (Application No. 201780087058.6) dated Jul.
17, 2020. cited by applicant .
English translation of International Preliminary Report on
Patentability (Chapter I) (Application No. PCT/JP2017/043714) dated
Sep. 6, 2019, 6 pages. cited by applicant.
|
Primary Examiner: Nouketcha; Lionel
Attorney, Agent or Firm: Burr & Brown, PLLC
Claims
What is claimed is:
1. An air conditioner comprising: an air flow path; a cooling unit
disposed in the air flow path, the cooling unit being configured to
cool air introduced into the air flow path so as to condense vapor
contained in the air; a humidification unit that humidifies the
air, the humidification unit including a storage tank for storing
water and a heater for heating water in the storage tank; a
discharged-water storage unit capable of storing water discharged
from the cooling unit and water discharged from the humidification
unit; a first exhaust pipe connected to the discharged-water
storage unit, the first exhaust pipe being configured to discharge
water stored in the discharged-water storage unit; a second exhaust
pipe having one end connected to the storage tank and another end
connected to an intermediate portion of the first exhaust pipe, the
second exhaust pipe being configured to discharge water from the
storage tank to the discharged-water storage unit; an exhaust valve
disposed midway on the second exhaust pipe; and an overflow pipe
that connects the storage tank and a part of the second exhaust
pipe on a downstream side of the exhaust valve.
2. The air conditioner according to claim 1, wherein the
discharged-water storage unit is a drain pan disposed below the
cooling unit.
3. The air conditioner according to claim 1, wherein a bottom wall
of the discharged-water storage unit is inclined with respect to a
horizontal plane.
4. The air conditioner according to claim 1, further comprising a
water level detector that detects a water level in the
discharged-water storage unit.
5. The air conditioner according to claim 1, further comprising a
pump that discharges water stored in the discharged-water storage
unit.
6. The air conditioner according to claim 5, wherein the pump is a
diaphragm pump.
Description
FIELD OF THE INVENTION
The present invention relates to an air conditioner.
BACKGROUND OF THE INVENTION
In a manufacturing step of semiconductors, an air conditioner has
been conventionally used for precisely controlling a temperature
and a humidity of an atmosphere. For example, JP 5886463 B1
discloses an air conditioner comprising a cooling unit that cools
and dehumidifies air having been introduced into the air
conditioner, a heating unit that heat air having passed through the
cooling unit up to a predetermined temperature, and a
humidification unit (humidification device) that humidifies air
having passed through the heating unit.
In the air conditioner of JP 5886463 B1, when air having been
introduced into the air conditioner is cooled in the cooling unit,
vapor contained in the air is condensed into water droplets which
adhere to the cooling unit. Thus, the air having been introduced
into the air conditioner is cooled and dehumidified. The water
droplets adhering to the cooling unit generally fall down to a
drain pan disposed below the cooling unit so as to be discharged to
the outside of the air conditioner through an exhaust pipe
connected to the drain pan.
The humidification unit has a storage tank for storing water and a
heater disposed in the storage tank. Water stored in the storage
tank is heated by the heater so as to be evaporated to generate
vapor, so that air passing above the storage tank is humidified. A
temperature of the heater is controlled such that a desired amount
of vapor can be generated. A water supply means having a water
supply pipe and a valve, such as an electromagnetic valve, is
connected to the storage tank. In the storage tank, a detector for
detecting a liquid level of water stored therein is disposed. Thus,
the liquid level height is controlled within a predetermined range.
Namely, when the detector detects that a liquid level in the
storage tank falls below a lower limit of the predetermined range
because the water is evaporated by being heated by the heater, the
valve of the water supply means is released so as to supply the
storage tank with water through the water supply pipe.
Thus, during a normal operation of the air conditioner, water is
not discharged from the humidification unit. However, upon
maintenance operation or long-term suspension, water in the
humidification unit is discharged. In this case, water in the
storage tank is manually moved by an operator to a container such
as a bucket through an exhaust pipe connected to the storage tank.
However, in this method, not only labor of an operator increases,
but also the discharge operation is time-consuming, resulting in
lowering of operation efficiency.
In addition, in order to allow a humidification unit to be operated
more stably, the inventors of the present invention consider that a
humidification unit is equipped with an overflow path, and that,
when a liquid level of water in the storage tank exceeds a
predetermined range because of trouble of a water supply valve or a
detector, water is discharged from the overflow path. In this case,
the air conditioner is required to have a means for discharging
water in the storage tank of the humidification unit, without any
manual operation of an operator.
In order to solve these problems, it is possible to provide a means
dedicated for automatically discharging water in the storage tank
to the outside of the air conditioner. However, in this case, the
number of components constituting the air conditioner increases,
and the air conditioner enlarges as a whole.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above
circumstances. The object of the present invention is to provide an
air conditioner equipped with a means for discharging water stored
in a humidification unit, while increase in the number of
components constituting the air conditioner and enlargement of the
air conditioner can be avoided.
The air conditioner of the present invention comprising:
an air flow path;
a cooling unit disposed in the air flow path, the cooling unit
being configured to cool air introduced into the air flow path so
as to condense vapor contained in the air;
a humidification unit that humidifies the air, the humidification
unit including a storage tank for storing water and a heater for
heating water in the storage tank;
a discharged-water storage unit capable of storing water discharged
from the cooling unit and water discharged from the humidification
unit; and
an exhaust pipe connected to the storage tank, the exhaust pipe
being configured to discharge water in the storage tank to the
discharged-water storage unit; and
an exhaust valve disposed midway on the exhaust pipe;
wherein the air conditioner further comprises an overflow pipe that
connects the storage tank and a part of the exhaust pipe on the
downstream side of the exhaust valve.
In the air conditioner of the present invention, the
discharged-water storage unit may be a drain pan disposed below the
cooling unit.
In the air conditioner of the present invention, a bottom wall of
the discharged-water storage unit may be inclined with respect to a
horizontal plane.
The air conditioner of the present invention may further comprise a
water level detector that detects a water level in the
discharged-water storage unit.
The air conditioner of the present invention may further comprise a
pump that discharges water stored in the discharged-water storage
unit.
In the air conditioner of the present invention, the pump may be a
diaphragm-type pump.
According to the present invention, it is possible to provide an
air conditioner equipped with a means for discharging water stored
in a humidification unit, while increase in the number of
components constituting the air conditioner and enlargement of the
air conditioner can be avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view for describing an embodiment of the present
invention, schematically showing an example of a semiconductor
device manufacturing plant where an air conditioner is
installed.
FIG. 2 is a view schematically showing an example of the air
conditioner.
FIG. 3 is a view showing a humidification unit of the air
conditioner.
FIG. 4 is a view for showing a cooling unit, the humidification
unit and a discharged-water storage unit of the air
conditioner.
FIG. 5 is a view for describing operation timings of a pump for
discharging water stored in the discharged-water storage unit.
FIG. 6 is an enlarged sectional view of the discharged-water
storage unit seen along an arrow VI of FIG. 4.
FIG. 7 is a view showing a cooling unit, a humidification unit and
a discharged-water storage unit of an air conditioner according to
a modification example of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Herebelow, an embodiment of the present invention is described with
reference to the drawings. In the drawings attached to the
specification, a scale size, an aspect ratio and so on are changed
and exaggerated from the actual ones, for the convenience of
easiness in illustration and understanding.
Further, terms specifying shapes, geometric conditions and their
degrees, e.g., "parallel", "orthogonal", "same", etc. and a value
of a length, an angle, etc., are not limited to their strict
definitions, but are to be construed to include a range capable of
exerting a similar function.
FIGS. 1 to 4 are views for describing an embodiment of the present
invention. FIG. 1 is a view for describing an embodiment of the
present invention, schematically showing an example of a
semiconductor device manufacturing plant where an air conditioner
is installed. FIG. 2 is a view schematically showing an example of
the air conditioner. FIG. 3 is a view showing a humidification unit
of the air conditioner. FIG. 4 is a view for showing a cooling
unit, the humidification unit and a discharged-water storage unit
of the air conditioner.
The semiconductor device manufacturing plant 1 shown in FIG. 1 has
an upstairs part 2 and a downstairs part 3. A semiconductor device
manufacturing apparatus 7 is installed in the upstairs part 2 of
the semiconductor device manufacturing plant 1. An air conditioner
10 that controls a temperature and a humidity of air and delivers
the air to the semiconductor device manufacturing apparatus 7 is
installed in the downstairs part 3. Herein, the upstairs part 2
means an upper floor part relative to the downstairs part 3. The
upstairs part 2 may not only be positioned directly above the
downstairs part 3, but may also be horizontally shifted from the
downstairs part 3. In addition, another space (floor) may be
disposed between the upstairs part 2 and the downstairs part 3.
The semiconductor device manufacturing apparatus 7 is an apparatus
that performs at least one step of respective steps for
manufacturing a semiconductor device. For example, the
semiconductor manufacturing apparatus 7 can be structured as an
apparatus for performing a pattern forming step of a semiconductor
device. In the pattern forming step of a semiconductor device, a
photoresist material is firstly applied onto a semiconductor
substrate, and then the resist material is exposed through a
photomask (reticle). When the photoresist material is a
positive-type material, an area to be removed in a succeeding
development step is exposed. On the other hand, when the
photoresist material is a negative-type material, an area to be
left in the development step is exposed. Then, an exposed area or
an unexposed area in the resist material is removed by a solvent or
the like. Thus, a resist pattern having a pattern corresponding to
the exposure pattern is formed on the semiconductor substrate.
Thereafter, the semiconductor substrate is etched by plasma etching
with the resist pattern as a mask. Thus, a semiconductor device
having a pattern corresponding to the resist pattern is
manufactured.
In the semiconductor device manufacturing step in the semiconductor
device manufacturing apparatus 7, a temperature and a humidity of
an atmosphere are required to be precisely controlled. Thus, the
air conditioner 10 is installed in the semiconductor device
manufacturing plant 1. Air whose temperature and humidity are
precisely controlled by the air conditioner 10 is delivered to the
semiconductor device manufacturing apparatus 7. In the example
shown in FIG. 1, water discharged from the semiconductor device
manufacturing apparatus 7 is discharged to the outside of the
semiconductor device manufacturing plant 1 through an upstairs
exhaust pipe 4 disposed in the upstairs part 2. In the present
case, for example, an exhaust means communicated with the outside
of the semiconductor device manufacturing plate 1 is not installed
in the downstairs part 3, as described above. Thus, the
semiconductor device manufacturing plant 1 is equipped with a
downstairs exhaust pipe 5 that extends from the downstairs part 3
to the upstairs part 2 so as to be connected to the upstairs
exhaust pipe 4 in the upstairs part 2. Water discharged from the
air conditioner 10 is discharged to the outside of the
semiconductor device manufacturing plant 1 through the downstairs
exhaust pipe 5 and the upstairs exhaust pipe 4.
In the example shown in FIG. 2, the air conditioner 10 comprises an
air flow path 12 through which air passes, a cooling unit 14, a
heating unit 16 and a humidification unit 20, which are
sequentially disposed in the air flow path 12, and a blower 18 that
drives air to pass through the air flow path 12. The air flow path
12 has an upstream opening 12a and a downstream opening 12b. The
downstream opening 12b is in communication with the blower 18. The
blower 18 has a fan, not shown. The fan is rotated by a not-shown
drive source, such as a motor, so that air having been sucked into
the air flow path 12 through the downstream opening 12b is
discharged from a discharge outlet 18a toward a blower pipe 19. The
blower pipe 19 extends from the air conditioner 10 to the
semiconductor device manufacturing apparatus 7. Air discharged from
the discharge outlet 18a of the air conditioner 10 is delivered to
the semiconductor device manufacturing apparatus 7 through the
blower pipe 19. Since the air in the air flow path 12 is sucked by
the blower 18 through the downstream opening 12b, outside air is
introduced into the air flow path 12 through the upstream opening
12a. Namely, the upstream opening 12a functions as an air
introduction port for introducing outside air into the air flow
path 12. The upstream opening 12a may be equipped with a filter
device for removing dusts contained in outside air. In this
specification, the term "upstream" means an upstream side of an air
flow generated by the operation of the blower 18 in the air flow
path 12, and the term "downstream" means a downstream side of an
air flow generated by the operation of the blower 18 in the air
flow path 12. In FIG. 2, an air flowing direction in the air
conditioner 10 is shown by arrows.
The cooling unit 14 is disposed in the air flow path 12, and has a
function for cooling air introduced into the air flow path 12 so as
to condense vapor contained in the air. The cooling unit 14 in this
embodiment has a variable refrigeration capacity, and may be for
example, an evaporator in a cooling circuit in which a compressor,
a condenser, an expansion valve and an evaporator are connected in
this order through pipes so that a heating medium circulates
therethrough. However, the cooling unit 14 may not necessarily have
a variable refrigeration capacity. Air having been introduced into
the air flow path 12 through the upstream opening 12a comes into
contact with the cooling unit 14 so as to be cooled, and goes
toward the heating unit 16 positioned on the downstream side of the
cooling unit 14. When the air having been introduced into the air
flow path 12 is cooled by the cooling unit 14, vapor contained in
the air is condensed into water droplets which adhere to the
cooling unit 14. In this embodiment, the water droplets adhering to
the cooling unit 14 fall down to a drain pan 41 disposed below the
cooling unit 14.
The heating unit 16 has a variable heating capacity, and has a
function for heating air that has been cooled and dehumidified by
the cooling unit 14. However, the heating unit 16 may not
necessarily have a variable heating capacity. The heating unit 16
is disposed on the downstream side of the cooling unit 14 in the
air flow path 12. An electric heater may be used as the heating
unit 16, for example. Not limited thereto, the heating unit 16 may
use at least a part of heat of a heating medium that has a high
temperature in the aforementioned cooling circuit. Air having
passed through the cooling unit 14 comes into contact with the
heating unit 16 so as to be heated. At this time, since an amount
of saturated vapor in the air heated by the heating unit 16
increases, a humidity that is a ratio of an amount of vapor
actually contained in the amount of the saturated vapor
decreases.
Next, the humidification unit 20 is described with reference to
FIGS. 2 and 3. The humidification unit 20 is disposed for
humidifying air that has been heated by the heating unit 16 so that
its humidity has lowered. Thus, the humidification unit 20 is
disposed on the downstream side of the heating unit 16.
Particularly in the example shown in FIG. 2, the humidification
unit 20 is disposed between the heating unit 16 and the downstream
opening 12b. In the example shown in FIG. 3, the humidification
unit 20 has a storage tank 22 for storing water, which is opened
upward into the air flow path 12, a heater 24 that is accommodated
in the storage tank 22 so as to heat water in the storage tank 22,
and a water level detector 26 for detecting a water level height in
the storage tank 22.
The storage tank 22 is a container for containing water for use in
humidifying air. The storage tank 22 has a box-like shape with an
opened upper surface, and is formed of a stainless plate member. In
the example shown in FIG. 2, a part of the storage tank 22 projects
to the outside of the air flow path 12. However, not limited
thereto, the storage tank 22 may be accommodated inside the air
flow path 12 as a whole, or the storage tank 22 may be disposed
outside the air flow path 12 as a whole, and the upper opening of
the storage tank 22 may be communicated with the air flow path
12.
The heater 24 is an electric heater, for example, and is used for
heating water in the storage tank 22 so as to generate vapor. A
heating amount of the heater 24 is adjustable, so that an amount of
vapor generated from water stored in the storage tank 22 can be
adjusted. Thus, a humidity of air passing through the air flow path
12 can be adjusted into a desired humidity.
A supply pipe 32 for supplying water into the storage tank 22 is
connected to the storage tank 22. A supply valve 33 is disposed
midway on the supply pipe 32. The supply pipe 32 is connected to a
water supply source, not shown, at an end opposed to the end
connected to the storage tank 22. Thus, by opening the supply valve
33, water can be supplied from the supply source into the storage
tank 22 through the supply pipe 32. In addition, by closing the
supply valve 33, supply of water from the supply source into the
storage tank 22 can be stopped. An electromagnetic valve may be
used as the supply valve 33, for example.
A water level detector 26 is a float switch, for example, and is
used for detecting a water level height in the storage tank 22.
When the water level detector 26 detects that the water level
height in the storage tank 22 becomes lower than a predetermined
height, the supply valve 33 is opened by a not-shown control unit
so that supply of water into the storage tank 22 is started. Thus,
the water level height in the storage tank 22 becomes elevated.
When the water level detector 26 detects that the water level
height in the storage tank 22 becomes the predetermined height, the
supply valve 33 is closed by the control unit so that the supply of
water from the supply source into the storage tank 22 is stopped.
Thus, the water level height in the storage tank 22 can be
constantly maintained within a predetermined range.
An exhaust pipe (second exhaust pipe) 34 for discharging water in
the storage tank 22 is connected to the storage tank 22. An exhaust
valve 35 is disposed midway on the exhaust pipe 34. The exhaust
pipe 34 is connected to a below-described exhaust pipe (first
exhaust pipe) 46 at an end opposed to the end connected to the
storage tank 22. By opening the exhaust valve 35, water can be
discharged from the storage tank 22 to a discharged-water storage
unit 40 through the exhaust pipe 34 and a first part 461 of the
exhaust pipe 46. In addition, by closing the exhaust valve 35,
discharge of water from the storage tank 22 to the discharged-water
storage unit 40 can be stopped. A manual switching valve or an
electromagnetic valve may be used as the exhaust valve 35, for
example. When water in the storage tank 22 is desired to be
discharged in order to perform a maintenance operation of the
humidifying unit 20, in order to prevent deterioration of water in
the storage tank 22 during a long-term suspension, or another
reason, by opening the exhaust valve 35, the water can be
discharged from the storage tank 22 to the discharged-water storage
unit 40 through the exhaust pipe 34 and the first part 461.
In the example shown in FIGS. 3 and 4, an overflow pipe 38 is
connected to the storage tank 22. One end of the overflow pipe 38
is opened above the water level detector 26 in the storage tank 22,
and the other end thereof is connected midway to the exhaust pipe
34. Particularly in the illustrated example, the other end of the
overflow pipe 38 is connected to a portion that is positioned
downstream side of the exhaust valve 35 of the exhaust pipe 34,
i.e., a portion that is positioned oppositely to the storage tank
22 with respect to the exhaust valve 35. In this case, water having
flown from the storage tank 22 into the overflow pipe 38 goes
toward the discharged-water storage unit 40 without passing through
the exhaust valve 35.
In the humidifying unit 20, if supply of water into the storage
tank 22 cannot be stopped because of trouble of the supply valve 33
or the water level detector 26, there is a possibility that the
water overflows from the storage tank 22 to enter surrounding units
so that the units are damaged. In order to prevent such a problem,
in the humidification unit in this embodiment, the overflow pipe 38
serving as an overflow path is connected to the storage tank 22.
When the liquid level height in the storage tank 22 becomes higher
than the predetermined range because of trouble of the supply valve
33 or the water level detector 26, water in the storage tank 22 is
discharged to the below-described discharged-water storage unit 40
through the overflow pipe 38, the exhaust pipe 34 and the
below-described first part 461 of the exhaust pipe 46. Thus, even
when supply of water into the storage tank 22 cannot be stopped
because of trouble of the supply valve 33 or the water level
detector 26, it can be prevented that the water overflows from the
storage tank 22 to enter surrounding units so that the units are
damaged, and the air conditioner 10 can have stability in
operation.
Next, the discharged-water storage unit 40 is described. The
discharged-water storage unit 40 is disposed for storing water
discharged from the cooling unit 14 and the water discharged from
the humidification unit 20. In the example shown in FIG. 4, the
discharged-water storage unit 40 is structured as the drain pan 41
disposed below the cooling unit 14. The exhaust pipe (first exhaust
pipe) 46 for discharging water stored in the discharged-water
storage unit 40 is connected to the discharged-water storage unit
40 (drain pan 41). In the illustrated example, the air conditioner
10 has a pump P for discharging water stored in the
discharged-water storage unit 40. The exhaust pipe 46 is connected
to the pump P at an end opposed to the end connected to the
discharged-water storage unit 40. In the illustrated example, the
exhaust pipe (second exhaust pipe) 34 for discharging water in the
storage tank 22 of the humidification unit 20 is connected to the
exhaust pipe 46 at a connection 48 positioned at an intermediate
portion of the exhaust pipe 46. Thus, the exhaust pipe 46 has the
first part 461 that extends from the discharged-water storage unit
40 to the connection 48, and a second part 462 that extends from
the connection 48 to the pump P. As described above, water droplets
adhering to the cooling unit 14 fall down into the discharged-water
storage unit 40 disposed below the cooling unit 14 so as to be
stored in the discharged-water storage unit 40. In addition, water
discharged from the storage tank 22 of the humidification unit 20
flows into the discharged-water storage unit 40 so as to be stored
therein through the exhaust pipe 34 and the exhaust pipe 46 (first
part 461) or through the overflow pipe 38, the exhaust pipe 34 and
the exhaust pipe 46 (first part 461).
In the example shown in FIG. 4, liquid level detectors 44, 45 that
detect water levels in the discharged-water storage unit 40 are
disposed in the discharged-water storage unit 40. Particularly in
the illustrated example, in the discharged-water storage unit 40,
there are a lower water level detector 44 disposed relatively
below, and a higher water level detector 45 disposed relatively
above. Float switches may be used as the water level detectors 44,
45, for example.
In the illustrated example, the exhaust pipe 46 (second part 462)
and the downstairs exhaust pipe 5 are connected by the pump P. When
the pump P is activated, water in the discharged-water storage unit
40 is delivered toward the downstairs exhaust pipe 5. In this
embodiment, the pump P is activated based on a water level
detection by each of the water level detectors 44, 45, so that
water in the discharged-water storage unit 40 is discharged.
The higher water level detector 45 is disposed below a lower end of
the upstream opening 12a of the air flow path 12, i.e., at a lower
position. In this case, when the pump P is activated based on the
detection of a water level by the higher water level detector 45 so
as to discharge water in the discharged-water storage unit 40,
water in the discharged-water storage unit 40 can be prevented from
overflowing from the upstream opening 12a of the air flow path 12.
The lower water level detector 44 is preferably disposed such that
it can detect a water level at a position as low as possible in the
discharged-water storage unit 40.
Activation of the pump P based on detection of water level by each
water level detector 44, 45 is described in detail with reference
to FIG. 5. When no water is stored in the discharged-water storage
unit 40, both the water level detectors 44, 45 do not detect a
water level, whereby the pump P is not activated. When water
discharged from the cooling unit 14 and/or water discharged from
the humidification unit 20 flows into the discharged-water storage
unit 40 so that a water level becomes elevated, the lower water
level detector 44 firstly detects the water level (timing A). When
the water level in the discharged-water storage unit 40 becomes
further elevated, the higher water level detector 45 then detects
the water level (timing B). When the not-shown control unit
receives a signal informing the detection of the water level from
the higher water level detector 45, the control unit activates the
pump P so that the water in the discharged-water storage unit 40 is
discharged through the exhaust pipe 46 toward the downstairs
exhaust pipe 5. When the water level in the discharged-water
storage unit 40 lowers by the activation of the pump P, the higher
water level detector 45 does not detect the water level any more
(timing C). Even when the higher water level detector 45 does not
detect the water level, the pump P is continuously activated. When
the water level in the discharged-water storage unit 40 further
lowers, the lower water level detector 44 does not detect the water
level any more. When the control unit receives a signal informing
that the water level is not detected from the lower water level
detector 44, or when a signal informing the detection of the water
level from the lower level detector 44 stops, the control unit
stops the pump P (timing D). Thus, in the air conditioner 10
according to this embodiment, discharge of water stored in the
discharged-water storage unit 40 is controlled such that, when a
water level in the discharged-water storage unit 40 reaches a
predetermined higher level, discharge of water from the
discharged-water storage unit 40 is started, and that, when a water
level in the discharged-water storage unit 40 reaches a
predetermined lower level, discharge of water from the
discharged-water storage unit 40 is stopped. The predetermined
lower level means a position that is relatively lower than the
predetermined higher level.
FIG. 6 is a view seen along an arrow VI of FIG. 4, which shows an
enlarged sectional view of the discharged-water storage unit 40. In
FIG. 6, an area corresponding to the upstream opening 12 of the air
flow path 12 is shown by broken lines.
In the example shown in FIG. 6, the discharged-water storage unit
40 (drain pan 41) has a bottom wall 42, and a sidewall 43 standing
up from a periphery of the bottom wall 42. In the illustrated
example, the bottom wall 42 is inclined with respect to a
horizontal plane, such that one side (right side in FIG. 6) in a
width direction (right and left direction in example shown in FIG.
6) is lowered. The term "width direction" herein includes all the
directions orthogonal to the vertical direction (up and down
direction in FIG. 6). Namely, the bottom wall 42 is not limited to
the bottom wall shown in FIG. 6, which is inclined such that one
side in the right and left direction is lowered. The bottom wall 42
may be inclined with respect to a horizontal plane such that one
end in a direction orthogonal to the sheet plane of FIG. 6 is
lowered. In addition, the bottom wall 42 may be inclined with
respect to a horizontal plane such that one side in the right and
left direction in the example shown in FIG. 6 is lowered, and that
one end in a direction orthogonal to the sheet plane of FIG. 6 is
lowered. The exhaust pipe 46 (first part 461) is opened toward the
discharged-water storage unit 40 at a position near an end on one
side in the width direction of the bottom wall 42. Herein, the
position near the end on one side in the width direction of the
bottom wall 42 means an area extending from the end on one side in
the width direction of the bottom wall 42 to an inside thereof by
1/10 of a width W.sub.42 of the bottom wall 42 along the width
direction. Since the bottom wall 42 is inclined with respect to a
horizontal plane, water stored in the discharged-water storage unit
40 flows toward the one side in the width direction, i.e., toward
the exhaust pipe 46 opened into the bottom wall 42, whereby water
can be rapidly discharged from the discharged-water storage unit
40.
A ratio (H.sub.42/W.sub.42) of a height H.sub.42 which is from the
lowest portion to the highest portion of the bottom wall 42 (in the
example shown in FIG. 6, the height H.sub.42 from the end on one
side in the width direction of the bottom wall 42 to the end on the
other side (left side in FIG. 6)) relative to the width W.sub.42 of
the bottom wall 42 may be not less than 1/200 and not more than
1/20, for example. When H.sub.42/W.sub.42 is not less than 1/200,
the bottom wall 42 can be appropriately inclined, whereby water can
be rapidly discharged from the discharged-water storage unit 40. In
addition, when H.sub.42/W.sub.42 is not more than 1/20, the height
of the discharged-water storage unit 40 can be held down, whereby
enlargement of the discharged-water storage unit 40 can be
effectively avoided.
In the example shown in FIG. 6, the water level detectors 44, 45
are both disposed above the position near the end on one side in
the width direction of the bottom wall 42. Since the bottom wall 42
is inclined with respect to a horizontal plane such that one side
in the width direction is lowered, a depth of water stored in the
discharged-water storage unit 40 from the water level down to the
bottom wall 42 increases toward the one side in the width
direction. In the illustrated example, the water level detectors
44, 45 are disposed on an area in which the depth of water stored
in the discharged-water storage unit 40 is relatively large. This
is because a water level in the discharged-water storage unit 40
waves by vibrations generated in the air conditioner 10. These
waves may make unstable detection of water level by the water level
detectors 44, 45. Thus, the water level detectors 44, 45 are
disposed on a deep area insusceptible to waves. As a result, the
water level detectors 44, 45 can stably detect water levels with
minimum wave influence. Thus, detection of water levels by the
water level detectors 44, 45 can be stably performed. In addition,
by disposing the lower water level detector 44 above the position
near the end on one side in the width direction of the bottom wall
42, i.e., by disposing the lower water level detector 44 on an area
in which the depth of water in the discharged-water storage unit 40
is relatively large, an amount of water remaining in the
discharged-water storage unit 40 can be reduced at a time point at
which discharge of water by the pump P is completed (timing D in
FIG. 5). Thus, an amount of water that can be discharged once by
the pump P is increased, whereby the number of times of activation
of the pump P can be reduced. Therefore, an energy amount consumed
by the pump P can be effectively reduced.
In the illustrated example, a gap is formed between an end in the
width direction of the cooling unit 14 and a side wall 13 of the
air flow path 12. A width of the gap, i.e., a separation distance
W.sub.a along the width direction between the end in the width
direction of the cooling unit 14 and the sidewall 13 of the air
flow path 12 may be not less than 100 mm and not more than 200 mm,
for example.
The width W.sub.42 of the bottom wall 42 is preferably the same as
a width W.sub.14 of the cooling unit 14 along the width direction,
or larger than the width W.sub.14 of the cooling unit 14. When the
bottom wall 42 has such a width, water droplets falling down from
the cooling unit 14 can be more reliably caught.
The air conditioner 10 in this embodiment includes: the air flow
path 12, the cooling unit 12 disposed in the air flow path 12, the
cooling unit 12 being configured to cool air introduced into the
air flow path 12 so as to condense vapor contained in the air; the
humidification unit 20 that humidifies the air, the humidification
unit 20 having the storage tank 22 for storing water and a heater
24 for heating water in the storage tank 22; the discharged-water
storage unit 40 capable of storing water discharged from the
cooling unit 14 and water discharged from the humidification unit
20; the exhaust pipe 23 connected to the storage tank 22, the
exhaust pipe 23 being configured to discharge water in the storage
tank 22 to the discharged-water storage unit 40; and the exhaust
valve 35 disposed midway on the exhaust pipe 34; wherein the air
conditioner 10 further includes the overflow pipe 38 that connects
the storage tank 22 and a part of the exhaust pipe 34 on the
downstream side of the exhaust valve 35.
According to such an air conditioner 10, since it has the
discharged-water storage unit 40 capable of storing water
discharged from the cooling unit 14 and water discharged from the
humidification unit 20, water discharged from the humidification
unit 20, together with water discharged from the cooling unit 14,
can be discharged to the outside of the air conditioner 10 without
any manual operation of an operator. Namely, it is possible to
automate the discharge operation of water discharged from the
humidification unit 20, which saves labor of an operator. In
addition, as compared with a case in which a means dedicated for
automatically discharging water discharged from the humidification
unit 20 to the outside of the air conditioner 10, increase in the
number of components constituting the air conditioner 10 and
enlargement of the air conditioner 10 can be avoided.
In addition, since the air conditioner 10 has the overflow pipe 38
that connects the storage tank 22 of the humidification unit 20 and
a part of the exhaust pipe 34, which is positioned on the
downstream side of the exhaust valve 35, even when supply of water
from the supply source into the storage tank 22 cannot be stopped
because of trouble of the supply valve 33 or the water level
detector 26, it can be prevented that the water overflows from the
storage tank 22 to enter surrounding units so that the units are
damaged, and the air conditioner 10 can have stability in
operation.
In the air conditioner 10 in this embodiment, the discharged-water
storage unit 40 is the drain pan 41 disposed below the cooling unit
14.
According to such an air conditioner 10, since the drain pan 41 can
be used as the discharged-water storage unit 40, increase in the
number of components constituting the air conditioner 10 and
enlargement of the air conditioner 10 can be further avoided.
In the air conditioner in this embodiment, the bottom wall 42 of
the discharged-water storage unit 40 is inclined with respect to a
horizontal plane.
According to such an air conditioner 10, since water stored in the
discharged-water storage unit 40 can flow along the inclination of
the bottom wall 42, the water can be rapidly discharged from the
discharged-water storage unit 40.
The air conditioner 10 in this embodiment further has the water
level detectors 44, 45 each detects a water level in the
discharged-water storage unit 40.
According to such an air conditioner 10, water in the
discharged-water storage unit 40 can be discharged based on
detection of water level by the water level detectors 44, 45. Thus,
discharge of water from the discharged-water storage unit 40 can be
automated.
The air conditioner 10 in this embodiment further has the pump P
that discharges water stored in the discharged-water storage unit
40.
According to such an air conditioner 10, discharge of water stored
in the discharged-water storage unit 40 can be efficiently
performed by the pump P. In addition, as shown in FIG. 1, in the
semiconductor device manufacturing plant 1, the downstairs part 3
is not equipped with an exhaust channel to the outside of the
semiconductor device manufacturing plant 1, and only the upstairs
part 2 is equipped with an exhaust channel to the outside of the
semiconductor manufacturing plant 1. Even in this case, water
stored in the discharged-water storage unit 40 can be delivered to
the upstairs part 2 by using the pump P.
The aforementioned embodiment can be variously modified. Herebelow,
modification examples are described with reference to the drawings.
In the below description and the drawings used in the description,
a part having the same structure as that of the above embodiment
has the same reference numeral, and description thereof is
omitted.
A modification example of the air conditioner 10 is described with
reference to FIG. 7. FIG. 7 is a view showing a cooling unit 14, a
humidification unit 20 and a discharged-water storage unit 40 of an
air conditioner 10 according to this modification example.
In the above embodiment, the drain pan 41 is used as the
discharged-water storage unit 40. On the other hand, in this
modification example, a discharged-water storage unit 40 separated
from the drain pan 41 is provided. In the illustrated example, the
discharged-water storage unit 40 is structured as a storage tank 51
disposed below the drain pan 41. However, the installation position
of the storage tank 51 is not limited to the position below the
drain pan 41. An exhaust pipe (third exhaust pipe) 47 for
discharging water droplets falling down to the drain pan 41 is
connected to the drain pan 41. The exhaust pipe 47 is connected to
the storage tank 51 at an end opposed to the end connected to the
drain pan 41. In the illustrated example, an exhaust pipe 34 for
discharging water in the storage tank 22 of the humidification unit
20 is connected to the exhaust pipe 47 at a connection 49
positioned on an intermediate part of the exhaust pipe 47. Thus,
the exhaust pipe 47 has a first part 471 that extends from the
drain pan 41 to the connection 49, and a second part 472 that
extends from the connection 49 to the storage tank 51. Water
droplets adhering to the cooling unit 14 fall down to the drain pan
41 disposed below the cooing unit 14 to flow into the storage tank
51 so as to be stored therein through the exhaust pipe 47. In
addition, water discharged from the storage tank 22 of the
humidification unit 20 flows into the storage tank 51 so as to be
stored therein through the exhaust pipe 34 and the exhaust pipe 47
(second part 472), or through the overflow pipe 38, the exhaust
pipe 34 and the exhaust pipe 47 (second part 472).
An exhaust pipe (fourth exhaust pipe) 52 for discharging water
stored in the storage tank 51 toward the pump P is connected to the
storage tank 51. The exhaust pipe 52 is connected to the pump P at
an end opposed to the end connected to the storage tank 51. Since
the operation of the pump P is the same as that of the above
embodiment, description thereof is omitted.
In the air conditioner 10 according to this modification example,
the discharged-water storage unit 40 has the storage tank 51
capable of storing water discharged from the cooling unit 14 and
water discharged from the humidification unit 20.
According to such an air conditioner 10, the position of the
storage tank 51 of the discharged-water storage unit 40 is not
limited to a position below the cooling unit 14. Thus, a degree of
freedom in design of the air conditioner 10 can be effectively
improved.
As another modification example, the pump P can be structured as a
diaphragm-type pump. A discharge amount in each discharge of a
diaphragm-type pump is known for every model. In addition, an
amount of water stored in the discharged-water storage unit 40 upon
detection of a water level by the higher water level detector 45 is
substantially constant. Thus, in the above embodiment, an operation
time of the pump P or the number of times of operation thereof is
set such that after the higher water level detector 45 has detected
a water level, the pump P discharges water, an amount of which is
estimated as an amount stored in the discharged-water storage unit
40, toward the downstairs exhaust pipe 5, and then stops. In this
case, the lower water level detector 44 can be omitted.
In the air conditioner 10 in this modification example, the pump P
is a diaphragm-type pump.
According to such an air conditioner 10, since the lower water
level detector 44 can be omitted, the number of components
constituting the air conditioner 10 can be reduced, which can cut
costs of the air conditioner 10.
Some modification examples of the aforementioned embodiment have
been described. Naturally, these modification examples can be
suitably combined.
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